Front-mountable injection molding nozzle

ABSTRACT

An injection molding apparatus includes a first, rear-mounted nozzle that is coupled to a manifold for receiving a melt stream therefrom. A second, front-mounted nozzle is coupled to the first nozzle by a nozzle link that is provided between the first and second nozzles. A plurality of gate seals are coupled to a forward end of the second nozzle. The gate seals receive melt from a plurality of melt passages and deliver the melt to a plurality of mold cavities through respective gates. The second nozzle is slidably removable from the first nozzle via the nozzle link to facilitate repair or replacement of the gate seals.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No.10/968,459, filed Oct. 20, 2004, now U.S. Pat. No. 7,179,081 and alsowhich is a continuation-in-part of U.S. application Ser. No. 10/819,165,filed Apr. 7, 2004, that claims the benefit under 35 U.S.C. § 119(e) ofprovisional U.S. Appl. No. 60/460,418 filed Apr. 7, 2003, the contentsof which are incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to an injection moldingapparatus and, in particular, to a front mountable nozzle that deliversmelt to a number of mold cavities spaced around the nozzle.

2. Related Art

Edge gating from a nozzle of an injection molding apparatus through anumber of edge gate seals is well known. A multi-cavity edge, or side,gated injection molding apparatus 100 is shown in FIG. 1 as described inU.S. Pat. No. 5,494,433 to Gellert, issued Feb. 27, 1996, which isincorporated in its entirety herein by reference thereto. Generally, themulti-cavity edge-gated injection molding apparatus 100 includes severalnozzles 102, one of which is shown in FIG. 1, that are coupled to amanifold 118 to receive a melt stream of moldable material therefrom.Each nozzle 102 is mounted in a cylindrical opening 104 in a mold 106 toconvey pressurized melt through a nozzle melt channel 108 to mold gates110, which lead to mold cavities 112 in mold 106. Mold cavities 112 arespaced radially around nozzle 102. Each mold gate 110 extends through agate insert 114, which is held in position by a gate insert retainerplate 122. Each mold gate 110 is aligned with a gate seal 116 that isthreadably coupled to nozzle 102. As such, the location of gate seals116 is generally fixed relative to the mold 106.

As illustrated in FIG. 1, manifold 118 is a “floating” manifold, whichis positioned below a back plate 120 and coupled to mold 106 throughnozzle 102. This arrangement allows for thermal expansion of manifold118 and nozzle 102 in an axial direction. In such an arrangement,requisite axial thermal expansion is accommodated by having asliding/telescopic arrangement between a sprue bushing 124 fixed to amold back plate 120 and manifold 118. However, axial thermal expansionof nozzle 102 is restricted in a direction of the mold cavity by therelatively fixed position of gate seals 1 16. Consequently, gate seals116 bear the load of both the manifold and the edge-gating nozzle duringoperation of the injection molding apparatus. Due to the strenuous andrepetitive nature of the injection molding process, such a loadcondition may cause misalignment of the gate seals with their respectivemold gates and excessive wear of the gate seals resulting in leakage andmore frequent repair and maintenance. In order to access gate seals 116for repair or maintenance purposes, edge-gated systems often requirethat the entire system be advanced forward or removed.

As such there exists a need in the injection molding industry for aninjection molding apparatus that maintains alignment of a plurality ofgate seals with a plurality of respective mold gates and that reducesthe load on the gate seals during operation and facilitates access formaintenance.

SUMMARY OF THE INVENTION

According to an embodiment of the present invention there is provided aninjection molding apparatus that during operation isolates horizontalgate seals of an edge-gated nozzle from a manifold load by having a dualnozzle arrangement between a mold cavity and the manifold. In thepresent invention, a rear-mounted nozzle takes the load of the manifoldand a front-mounted nozzle with horizontal gate seals is allowed tofloat freely in order to compensate for misalignment caused by heatexpansion during operation. As such, the edge-gated, front-mountednozzle functions to keep the gate seals properly located to maintain agood seal with each corresponding mold gate.

Each rear-mounted nozzle includes a flange that is held in acorresponding shoulder of a mold plate to limit axial movement of therear-mounted nozzle in the direction of the front-mounted nozzle. Therear-mounted nozzle flange and mold plate shoulder arrangement supportsthe load from the manifold but still allows the load from the manifoldto be used as sealing means/force between the rear-mounted nozzle andthe manifold.

The present invention includes a telescoping linking piece having a meltpassage of a relatively constant diameter there through that is used tofluidly connect the melt channels of the rear- and front-mounted nozzlesand to accommodate the thermal expansion of the rear-mounted nozzle andthe front-mounted nozzle during operation.

An embodiment of the present invention includes an axially-fixedmanifold having a manifold channel for receiving a melt stream ofmoldable material under pressure and for delivering the melt stream to afirst nozzle melt channel of a first nozzle. The first nozzle having aflange for seating in a corresponding shoulder of a mold plate. Asecond, edge-gated nozzle is coupled to a forward end of the firstnozzle, the second nozzle having a second nozzle melt channel forreceiving the melt stream from the first nozzle melt channel.

This embodiment of the present invention includes a nozzle link having amelt passage of a relatively constant diameter that fluidly couples thefirst nozzle melt channel and the second nozzle melt channel. A firstend of the nozzle link is threadably engaged with the first nozzle and asecond end of the nozzle link is slidingly insertable into an aperturein the second nozzle to provide for the second nozzle being slidablyremovable from the first nozzle with removal of the mold plate.

The second nozzle is provided with a plurality of melt passages thatextend from a forward end of the second nozzle melt channel fordirecting the melt stream toward a plurality of gate seals coupledthereto. A plurality of mold cavities are arranged about the forward endof the second nozzle to receive the melt stream from the plurality ofgate seals through a plurality of mold gates. The gate seals arerelatively fixed in position in an axial direction to provide horizontalalignment with the mold gates of the mold cavities.

The present invention provides an advantage in that the gate seals bearonly the load of the second nozzle instead of bearing the load of theentire manifold system. The present invention provides a furtheradvantage in that the gate seals are more easily accessible for repair,routine maintenance, and/or replacement purposes. In addition, anembodiment of the present invention that includes a heater wrapped abouta top and bottom surfaces of a second nozzle provides even heating ofthe melt, as well as greater thermal control of the melt in the nozzletip area for improved thermal gating. Also a puck-shaped and/orbrick-shaped second nozzle in accordance with the present inventionaccommodates more mold gates in a smaller area, i.e., reduces the pitchbetween nozzle tips to provide more locations for nozzle tips radiatingand/or extending from a melt channel of the second nozzle to increaseproduction of an injection molding apparatus.

In another embodiment of the present invention, a second nozzle includesa longitudinally extending second nozzle melt channel with a pluralityof melt passages that extend at an angle from a forward end of thesecond nozzle melt channel for directing the melt stream toward aplurality of gate seals coupled thereto. The gate seals are relativelyfixed in position to provide alignment with a plurality of mold gates.

BRIEF DESCRIPTION OF THE FIGURES

An embodiment of the present invention will now be described more fullywith reference to the accompanying drawings where like reference numbersindicate similar structure.

FIG. 1 is a partial cross-sectional view of a conventional edge-gatedinjection molding apparatus.

FIG. 2 is a partial cross-sectional view of a portion of an injectionmolding apparatus according to an embodiment of the present invention.

FIG. 3 is an enlarged view of a portion of FIG. 2.

FIG. 4 is an enlarged view of a portion of FIG. 3.

FIG. 5 is a partial cross-sectional view of an edge-gated systemaccording to another embodiment of the present invention.

FIG. 6 is a cross-sectional view of an injection molding apparatus inwhich the present invention may be used.

FIG. 7 is a partial cross-sectional view of a portion of an injectionmolding apparatus according to an embodiment of the present invention.

FIG. 8 is a partial cross-sectional view of the embodiment of FIG. 7 ina portion of an edge-gated system.

FIG. 9 is a perspective view of the apparatus as shown in FIG. 8 with amold plate removed.

FIG. 10 is a schematic side view of a portion of an injection moldingapparatus according to an embodiment of the present invention.

FIG. 11 is a view on 11-11 of FIG. 10.

FIG. 12 is a schematic side view of a portion of an injection moldingapparatus according to an embodiment of the present invention.

FIG. 13A is a view on 13-13 of FIG. 12.

FIG. 13B is a view on 13-13 of FIG. 12 showing another embodiment of thepresent invention.

FIG. 14 is a partial cross-sectional view of a portion of an injectionmolding apparatus according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is intended to be used in an injection moldingenvironment as shown in FIG. 6, which is a partial cross-sectional viewof an injection molding system 600. A manifold melt channel 602 extendsthrough a hot runner manifold 604 and is in fluid communication with amelt source from a machine nozzle (not shown) via a sprue bushing 606. Anozzle 610 is positioned within a nozzle cutout 608 of a cavity plate609. A nozzle melt channel 612 of nozzle 610 is in fluid communicationwith manifold melt channel 602 for receiving a melt therefrom.Particularly, the melt passes from manifold melt channel 602 through amanifold outlet 603 into nozzle melt channel 612. Nozzle melt channel612 carries the melt through a nozzle tip 613 towards a mold gate 614that leads to a mold cavity 616. Injection molding apparatus 600includes heaters 615 positioned about nozzle 610 and cooling channels617 in mold-plate 609.

An edge-gated injection molding apparatus in accordance with the presentinvention is illustrated in FIGS. 2-4 and is generally indicated byreference numeral 10. Injection molding apparatus 10 includes a manifold12 that is located between a mold plate 22, a sprue bushing 24 and aback plate 26. A disk 28 restricts movement of the manifold 12 relativeto the mold plate 22 and back plate 26 to axially fix the position ofmanifold 12. As such during operation, the manifold is effectivelyprevented from flexing in a direction of the back plate due to thermalexpansion. An air space 27 is provided between the manifold 12 and theback plate 26. A machine nozzle (not shown) delivers a melt stream ofmolten material under pressure to a manifold channel 14 of the manifold12 through sprue bushing 24. The disk 28 also helps to focus the forcefrom manifold 12 directly over first nozzle 16 to aid in sealingmanifold 12 to first nozzle 16. Disk 28 maintains insulating air gap 27between manifold 12 and back plate 26. Generally this disk is designedto provide minimum contact between manifold 12 and back plate 26 and iscapable of flexing to absorb some of the forces therebetween.

A plurality of first, rear-mounted nozzles 16 are coupled to themanifold 12. Each first nozzle 16 includes a first nozzle melt channel18 that is aligned with a respective manifold outlet 20 to receive themelt stream from the manifold channel 14. Each first nozzle 16 has aflange portion 19 that sits in a corresponding shoulder portion 21 ofmold plate 22. The flange being held in the corresponding shoulder ofthe mold plate acts to limit axial movement of the rear-mounted nozzlein the direction of a front-mounted nozzle 42 described below. Duringoperation, the rear-mounted nozzle flange and mold plate shoulderarrangement supports the load from the manifold while still allowing theload from the manifold to be used as a sealing means/force between therear-mounted nozzle and the manifold.

A nozzle body portion 23 of first nozzle 16 extends through an opening38, which extends through mold plate 22 and a cavity plate 40. Nozzleheaters 32 are coupled about nozzle body 23 of each first nozzle 16 toprovide heat thereto. The nozzle heaters 32 are in communication with apower source (not shown) through an electrical connector 34. Athermocouple 36 is coupled to the first nozzle 16 to provide temperaturemeasurements thereof.

With reference to FIGS. 2 and 3, a second, front-mounted nozzle 42 isshown coupled to the first, rear-mounted nozzle 16 by a nozzle link 44,which is described in greater detail below. The second nozzle 42 is anedge-gating nozzle that includes a second nozzle melt channel 46, whichis aligned with the first nozzle melt channel 18 of first nozzle 16 forreceiving melt therefrom. Gate seals 52 having melt passages 48laterally extend from second nozzle melt channel 46 to deliver meltthrough gates 50 to a series of mold cavities 55. Mold cavities 55 areradially spaced around an edge-gated tip portion of the second nozzle42, as illustrated in FIG. 2.

With reference to FIG. 2, gate seals 52 threadably engage the secondnozzle 42 to deliver melt from the melt passages 48 to mold cavities 55via gates 50. The structure surrounding each gate seal 52 includes agate insert 51 that is retained by a gate insert retainer 53. Such anarrangement is shown and described in U.S. Pat. No. 5,536,195 to Gellertthat is incorporated by reference in its entirety herein.

In the embodiment of FIGS. 2 and 3, gate seals 52 are of a two partconstruction including a tip 54 that is surrounded by a seal 56. Thegate seal 52 may be bi-metallic, for example, the seal 56 may becomprised of H13 steel and the tip 54 may be comprised of carbide orberyllium copper. The seal 56 and tip 54 are not limited to beingmetallic and therefore, the gate seal 52 may be comprised of anysuitable material combination. The seal 56 and the tip 54 mayalternatively be comprised of the same material. Gate seals 52 arelongitudinally-fixed in position relative to each respective mold gate50 and mold cavity due to the gate insert and the gate insert retainer,as shown with reference to the embodiment of FIG. 5.

The second nozzle 42 includes a projection 58 that further locates thesecond, front-mounted nozzle 42 relative to the cavity plate 40. Nozzleheaters 60 and thermocouples 36 a are coupled to each second nozzle 42to measure a temperature of the nozzle and provide heat thereto. Thenozzle heaters 60 are in communication with a power source (not shown)through an electrical connector 62.

In the embodiment of the present invention illustrated in FIG. 4, nozzlelink 44 includes a first end 64, which is threaded for engaging firstnozzle 16 and a second end 68 for engaging the second nozzle 42. Firstend 64 is disposed in an aperture 71 of a forward end 66 of first nozzle16. Aperture 71 has corresponding threads to engage the threads of firstend 64 of nozzle link 44. The second end 68 of nozzle link 44 is nestedin an aperture 72 that is provided in a rear end 65 of second nozzle 42.The second end 68 has a smooth outer surface 70 to allow second nozzle42 to be slidably removed from the nozzle link 44. The nozzle link 44includes a melt passage 78 of a constant diameter, which allows melt toflow from the first nozzle melt channel 18 to the second nozzle meltchannel 46 without a discernable drop in pressure therebetween.

In cold conditions, a gap 73 is maintained between second end 68 ofnozzle link 44 and aperture 72 of second nozzle 42. In operatingconditions with the high temperatures thereof, gap 73 of nozzle link 44is reduced or even consumed by the thermal expansion of the first andsecond nozzles. A collapsible O-ring 74 is provided between aperture 72of second nozzle 42 and second end 68 of nozzle link 44 for sealingpurposes so that melt does not escape. In the embodiment of the presentinvention shown in FIG. 4, a tooling projection 76 having a hexagonalouter profile is provided to facilitate installation and removal of thenozzle link 44.

Nozzle link 44 of the present invention allows second nozzle 42 to beremoved from first nozzle 16 for repair and maintenance purposes bysliding second nozzle 42 off of nozzle link 44. Further nozzle link 44is sized to accommodate the thermal expansion, i.e., axial growth, ofthe first and second nozzles that occurs at the high operatingtemperatures of an injection molding process. Accordingly in thisembodiment of the present invention during operation of the injectionmolding apparatus, thermal expansion of second nozzle 42 and firstnozzle 16 relative to each other is accommodated by gap 73 of nozzlelink 44.

In one embodiment of the present invention, nozzle link 44 may be madefrom a material having a higher thermal conductivity than the nozzles,such that during operation it will expand within aperture 72 of secondnozzle 42 to provide an additional sealing means.

In operation, edge-gated injection molding apparatus 10 is heated to anoperating temperature, which causes the components including themanifold 12 and first and second nozzles 16, 42 to expand. Manifold 12is relatively fixed in position on one surface by the interactionbetween disk 28 and back plate 26 and on the other surface by firstnozzle 16, more particularly by the interaction between flange 19 offirst nozzle 16 and shoulder 21 of mold plate 22. Gate seals 52 of anedge-gated tip portion of second nozzle 42 are also relatively fixed inposition with respect to mold gates 50. As such, the thermal expansionof the system is accommodated by the interaction of nozzle link 44 withfirst and second nozzles 16, 42.

A melt stream of molten material is delivered under pressure from amachine nozzle (not shown) to manifold channel 14 of manifold 12. Themelt is distributed from manifold channel 14 to nozzle melt channels 18of a plurality of first nozzles 16. The melt flows from the nozzle meltchannels 18, through melt passages 78 of nozzle links 44 and into thesecond nozzle melt channels 46. From the second nozzle melt channels 46,the melt is conveyed through melt passages 48, through gate seals 52,past gates 50 and into a respective mold cavity. Once the injectionportion of the cycle is complete, the molded parts are cooled andejected from the mold cavities.

An edge-gated injection molding apparatus in accordance with anotherembodiment of the present invention is illustrated in FIG. 5 and isgenerally indicated by reference numeral 510. Injection moldingapparatus 510 includes a manifold 512 having a manifold channel 514 andis relatively fixed in position as described above with reference to theembodiment of FIGS. 2-4.

In this embodiment a plurality of first, rear-mounted nozzles 516 arefluidly coupled to the manifold 512, each of which includes a firstnozzle melt channel 518 fluidly coupled to a respective manifold channel514. First nozzle 516 includes a body portion 523 that extends throughan opening 538 of a mold plate 522 and a cavity plate 540. Each firstnozzle 516 also includes a flange portion 519 that sits in acorresponding shoulder portion 521 of mold plate 522. The flange beingheld in the corresponding shoulder of the mold plate to act in limitingaxial movement of the rear-mounted nozzle in the direction of afront-mounted nozzle 542 described below. During operation, therear-mounted nozzle flange and mold plate shoulder arrangement acts inthe same manner as described above with reference to the embodiment ofFIGS. 2-4.

The embodiment of the present invention illustrated in FIG. 5 includes asecond, front-mounted nozzle 542 fluidly coupled to first nozzle 516 bya nozzle link 544, which is described in greater detail below. Secondnozzle 542 is an edge-gating nozzle that includes a second nozzle meltchannel 546 for receiving melt from first nozzle melt channel 518.Radially extending melt passages 548 branch out from second nozzle meltchannel 546 to deliver melt through gates 550 to a series of moldcavities 555. Mold cavities are radially spaced around an edge-gated tipportion of second nozzle 542. The structure surrounding mold cavities555 includes a gate insert 551 that is retained by a gate insertretainer 553.

One-piece gate seals 552 threadably engage second nozzle 542 to delivermelt from melt passages 548 to mold cavities 555 via mold gates 550.Each gate seal 552 is longitudinally fixed in position relative to eachrespective mold gate 550 and mold cavity 555 due to its respective gateinsert 551 and gate insert retainer 553 being fixed within a mold plate540.

As illustrated in FIG. 5, each of first nozzle 516 and second nozzle 542includes a heater 532, 560 and respective thermocouples 536, 536 a forheating the melt therein. In the embodiment, nozzle link 544 is coupledto first nozzle 516 and second nozzle 542 in a similar manner asdescribed above with a gap 573 between nozzle link 544 and an apertureof second nozzle 542. Nozzle link 544 includes a: melt passage 578 of aconstant diameter, which allows melt to flow from first nozzle meltchannel 518 to second nozzle melt channel 546 without an undesirabledrop in pressure therebetween. In this embodiment, an O-ring is not usedand a sealing force is achieved during operation by the thermalexpansion of first nozzle 516 and second nozzle 542 within gap 573 ofnozzle link 544.

The embodiment of the present invention of FIG. 5 operates in a likemanner as described above with reference to the embodiment of FIGS. 2-4.

An edge-gated injection molding apparatus in accordance with anotherembodiment of the present invention is illustrated in FIGS. 7-9 and isgenerally indicated by reference numeral 810. Injection moldingapparatus 810 includes a manifold (not shown) and is relatively fixed inposition as described above with reference to the embodiment of FIGS.2-4.

In this embodiment, a plurality of first, rear-mounted nozzles 716 arefluidly coupled to the manifold, each of which includes a first nozzlemelt channel 718 fluidly coupled to a respective manifold channel (notshown). First nozzle 716 includes a body portion 723 that extendsthrough an opening 838 of a mold plate 822. Each first nozzle 716 alsoincludes a flange portion 719 that sits against mold plate 822. Flangeportion 719 may be removable or an integral portion of first nozzle 716.When installed in an injection molding apparatus, the flange is heldagainst the mold plate and acts to limit axial movement of therear-mounted nozzle in the direction of a front-mounted nozzle 742described below. During operation, the nozzle flange and mold platearrangement acts in the same manner as described above with reference tothe embodiment of FIGS. 2-4.

The embodiment of the present invention illustrated in FIGS. 7-9includes second, front-mounted nozzle 742 fluidly coupled to firstnozzle 716 by a nozzle link 744, which is described in greater detailbelow. Second nozzle 742 is an edge-gating nozzle that includes a secondnozzle melt channel 746 for receiving melt from first nozzle meltchannel 718. Radially extending melt passages 748 branch out from secondnozzle melt channel 746 to deliver melt through gates 850 to a series ofmold cavities 855. Mold cavities are radially spaced around anedge-gated tip portion of second nozzle 742. Second nozzle 742 has asubstantially puck-shaped nozzle body 741 with a circular flange portion787 extending from a back surface 883 and a projection 858 extendingfrom a front surface 881. Projection 858 locates second nozzle 742relative to a mold cavity plate 840 to align gates seals 752 with moldgates 850, and to reduce lateral and longitudinal movement of secondnozzle 742.

Gate seals 752 threadably engage second nozzle 742 to deliver melt frommelt passages 748 to mold cavities 855 via mold gates 850. Each gateseal 752 is longitudinally fixed in position relative to each respectivemold gate 850 and mold cavity 855 as shown in FIG. 8. Gate seals 752 canbe a two-piece seal, as shown and described above with respect to theembodiment of FIGS. 2 and 3. In the alternative, gate seal 752 can be aone-piece arrangement as shown and described with respect to theembodiment of FIG. 5.

As illustrated in FIG. 7, each of first nozzle 716 and second nozzle 742includes a heater 732, 760 and respective thermocouples 736, 736 a forheating the melt therein. The nozzle heaters 732, 760 are incommunication with a power source (not shown) through respectiveelectrical connectors 734, 762. In the present embodiment as shown inFIGS. 8 and 9, heater 760 wraps around a front surface 881 to backsurface 883 of second nozzle 742 to beneficially surround gate seals 752with heat.

In the embodiment of FIGS. 7-9, nozzle link 744 is coupled to firstnozzle 716 and second nozzle 742 in a similar manner as described abovewith a seal 785 between a forward end 768 of nozzle link 744 and flange787 of second nozzle 742. Seal 785 prevents melt leakage and absorbs theforces of thermal expansion of nozzle link 744. In one embodiment, seal785 may be made of an insulative material to prevent heat loss at theslidable connection between the nozzle link and second nozzle. Althoughnot shown, nozzle link 744 may seat within flange 787 of second nozzle742 such that a gap is present between a forward end of the nozzle linkand back surface 883 of second nozzle 742 during cold conditions.

Nozzle link 744 includes a melt passage 778 of a constant diameter,which allows melt to flow from first nozzle melt channel 718 to secondnozzle melt channel 746 without an undesirable drop in pressuretherebetween.

The embodiment of the present invention of FIGS. 7-9 operates in a likemanner as described above with reference to the embodiments of FIGS.2-5.

An edge-gated injection molding apparatus in accordance with anotherembodiment of the present invention is illustrated in FIGS. 10 and 11and is generally indicated by reference numeral 1010. This embodiment issimilar to the embodiment of FIGS. 7-9, however, second, front mountednozzle 1042 has a substantially brick-shaped body.

Injection molding apparatus 1010 includes a manifold 1012 that isrelatively fixed in position as described above with reference to theembodiment of FIGS. 2-4. A first, rear mounted nozzle 1016 having afirst nozzle melt channel 1018 is coupled to the manifold 1012. Firstnozzle melt channel 1018 receives melt from a manifold channel 1014.Second, front mounted nozzle 1042 is an edge-gating nozzle that includesa second nozzle melt channel 1046 for receiving melt from the firstnozzle melt channel 1018 and distributing the melt to a plurality ofmelt passages 1048. The second nozzle 1042 is coupled to the firstnozzle 1016 by a nozzle link 1044, which includes a melt passage 1078.Nozzle link 1044 is similar to the nozzle links 44, 544 and 744 of thepreviously described embodiments and therefore will not be described indetail here. In the cold condition, a gap (not shown) may be presentbetween a forward end 1068 of the nozzle link 1044 and an aperture 1072of the second nozzle 1042, in which the forward end 1068 is seated.Further, a seal may surround the forward end 1068 of the nozzle link1044 similar to the embodiment of FIGS. 7-9.

Melt passages 1048 branch outwardly from a connector melt channel 1049that links the second nozzle melt channel 1046 to the melt passages 1048to deliver melt through gates 1050 to a series of mold cavities (notshown). The mold cavities are spaced about substantially brick shapedbody 1041 of the second nozzle 1042. The second nozzle 1042 may be anyshape in which the length of the second nozzle 1042, as measured alongan axis of the second nozzle melt channel 1046 of the second nozzle1042, is less than one or both of the width and the depth of the secondnozzle 1042. In the substantially puck-shaped embodiment of FIGS. 7-9,the width and the depth are equal to the diameter of the circular frontand back surfaces 881, 883 of the second nozzle 742, such that thelength of second nozzle 742 is less than the width/depth of the secondnozzle.

Gate seals 1052 threadably engage second nozzle 1042 to deliver meltfrom melt passages 1048 to the mold cavities via mold gates 1050. Eachgate seal 1052 is longitudinally fixed in position relative to eachrespective mold gate 1050. Gate seals 1052 may be of a two piececonstruction, as shown in FIGS. 2 and 3, or a one piece construction, asshown in FIG. 5. First and second nozzles 1016 and 1042 are furtherprovided with first and second heaters (not shown) respectively andfirst and second thermocouples (not shown). The second heater of secondnozzle 1042 wraps around a front surface 1081 to a back surface 1083 ofsecond nozzle 1042 to heat the gate seals 1052, similar to theembodiment shown in FIGS. 7-9.

The embodiment of FIGS. 10 and 11 operates in a like manner as describedabove with reference to the embodiments of FIGS. 2-5 and 7-9.

An injection molding apparatus in accordance with another embodiment ofthe present invention is illustrated in FIG. 12 and is generallyindicated by reference numeral 1110. In this embodiment, a first, rearmounted nozzle 1116 having a first nozzle melt channel 1118 is coupledto a manifold 1112. First nozzle melt channel 1118 receives melt from amanifold channel 1114. A second, front mounted nozzle 1142 is includes asecond nozzle melt channel 1146 for receiving melt from the first nozzlemelt channel 1118 and distributing the melt to a plurality of meltpassages 1148. The second nozzle 1142 is coupled to the first nozzle1116 by a nozzle link 1144 having a melt passage 1178. Nozzle link 1144is similar to the nozzle links 44, 544, 744 and 1044 of the previousembodiments and therefore will not be described in detail here. In thecold condition, a gap (not shown) may be present between a forward end1168 of the nozzle link 1144 and an aperture 1172 of the second nozzle1142, in which the forward end 1168 is seated. Further, a seal maysurround the forward end 1168 of the nozzle link 1144 similar to theembodiment of FIGS. 7-9.

A connector melt channel 1149 receives melt from the second nozzle meltchannel 746 and distributes the melt to melt passages 1148, which extendforward from the connector melt channel 1149. The melt passages 1148deliver melt through gates 1150 to a series of mold cavities (notshown), which are located forward of second nozzle 1142. As shown inFIG. 13A, second nozzle 1142 includes a substantially puck-shaped body1141. Gate seals 1152 threadably engage second nozzle 1142 and areevenly spaced about a generally circular front surface 1181 of thesecond nozzle 1142. Gate seals 1152 deliver melt from melt passages 1148to the mold cavities via mold gates (not shown). Each gate seal 1152 islongitudinally fixed in position relative to its respective mold gate.In one embodiment, second nozzle 1142 includes a projection (not shown)on a front surface that cooperates with a recess within a mold cavityplate (not shown) to longitudinally fix the position of gate seals 1152relative to their respective mold gates, similar to projection 858 andmold cavity plate 840 of FIG. 8. In a further embodiment, second nozzle1142 maybe positioned between cavity plates (not shown) proximate itsfront and back surfaces that cooperate to longitudinally fix theposition of gate seals 1152 relative to their respective mold gates.

Gate seals 1152 may be of a two piece construction, as shown in FIGS. 2and 3, or a one piece construction, as shown in FIG. 5. First and secondnozzles 1116 and 1142 are respectively provided with first and secondheaters (not shown) and first and second thermocouples (not shown). Thesecond heater may wrap around a front surface 1181 to a back surface1183 of second nozzle 1142 to heat the gate-seals 1152 in a similarmanner as the second heater in the embodiment of FIGS. 7-9.

Referring to FIG. 13B, another embodiment of an injection moldingapparatus 1210 is shown. This embodiment is similar to the embodiment ofFIGS. 12 and 13A, however, instead of a substantially puck-shaped body,second nozzle 1242 includes a substantially brick shaped body 1241.

Injection molding apparatus 1210 includes gate seals 1252 thatthreadably engage second nozzle 1242 and are spaced about a generallyrectangular shaped front surface 1281 of the second nozzle 1242. Thegate seals 1252 deliver melt from melt channels (not shown) that receivemelt from second nozzle melt channel (not shown) of second nozzle 1242to mold cavities (not shown).

FIG. 14 is a partial cross-sectional view of a portion of an injectionmolding apparatus according to another embodiment of the presentinvention. Similar to the embodiment shown in FIGS. 7-9, a first nozzle1416 connects to a nozzle link 1444 that is slidably coupled to acircular flange portion 1487 of a second nozzle 1442. Similarly shown isthe arrangement of first nozzle 1416 and second nozzle 1442 between amanifold 1412, a back plate 1426, mold plates 1422, 1440 and a gateinsert retainer 1453, the function of each in this arrangement isapparent to one of ordinary skill in the art. However in the embodimentshown in FIG. 14, second nozzle 1442 includes a second nozzle meltchannel 1446 with a plurality of melt passages 1448 that extend at anangle from a forward end of the second nozzle melt channel. Meltpassages 1448 are angled to guide a melt stream toward a plurality ofgate seals 1452 coupled to angled forward surfaces 1441 of second nozzle1442. Due to the arrangement of the first and second nozzles and thenozzle link, the gate seals may be relatively fixed in position toprovide alignment with a plurality of mold gates, because thermalexpansion during operation is accommodated by nozzle link 1444, asdescribed above with reference to the previous embodiments.

Accordingly, the embodiments of the present invention do not requirethat the manifold “float” to accommodate the thermal expansion of thesystem during operation. Instead, the manifold and nozzle gate seals mayboth be relatively fixed in longitudinal position because the nozzlelink allows for thermal expansion within the intersection of the firstand second nozzles.

In each embodiment of the present invention described above, in order togain access to the gate seals or the second nozzles for repair orregular scheduled maintenance, the cavity plate need only be removedwithout disturbing the remainder of the injection molding apparatus. Thesecond nozzle may then be slidably removed from the nozzle link to allowfor repair or replacement. The gate seals are also removable from thesecond nozzles and may similarly be repaired or replaced.

The many features and advantages of the invention are apparent from thedetailed specification and, thus, it is intended by the appended claimsto cover all such features and advantages of the invention that fallwithin the true spirit and scope of the invention. Further, sincenumerous modifications and changes will readily occur to those skilledin the art, it is not desired to limit the invention to the exactconstruction and operation illustrated and described, and accordinglyall suitable modifications and equivalents may be resorted to, fallingwithin the scope of the invention.

1. An injection molding apparatus comprising: a manifold having at leastone manifold melt channel for receiving a melt stream of moldablematerial under pressure; a first nozzle having a first nozzle meltchannel in fluid communication with said manifold melt channel; a secondnozzle having a second nozzle body, a second nozzle melt channel influid communication with said first nozzle melt channel and a pluralityof outwardly extending melt passages in fluid communication with saidsecond nozzle melt channel, said nozzle body having a length measuredalong a longitudinal axis of the second nozzle, a width and a depth; anozzle link provided between the first nozzle and the second nozzle andhaving a nozzle link melt passage for fluidly coupling the first nozzlemelt channel and the second nozzle melt channel, the nozzle link beingthreadably attached to the first nozzle and slidable within an apertureof the second nozzle; and a plurality of gate seals coupled to saidsecond nozzle, said plurality of gate seals for delivering the meltstream from said plurality of outwardly extending melt passages to aplurality of mold cavities through respective mold gates, wherein thelength of said second nozzle body is less than at least one of saidwidth and said depth of said second nozzle body.
 2. The injectionmolding apparatus of claim 1, wherein said plurality of outwardlyextending melt passages extend radially from said second nozzle meltchannel to said plurality of mold cavities.
 3. The injection moldingapparatus of claim 1, further comprising: a connector melt channelprovided between said second nozzle melt channel and said plurality ofoutwardly extending melt passages.
 4. The injection molding apparatus ofclaim 2, wherein said second nozzle body is substantially puck-shaped.5. The injection molding apparatus of claim 3, wherein said secondnozzle body is substantially puck-shaped.
 6. The injection moldingapparatus of claim 5, wherein said outwardly extending melt passagesextend toward a front end of said second nozzle.
 7. The injectionmolding apparatus of claim 3, wherein said nozzle body is substantiallybrick-shaped.
 8. The injection molding apparatus of claim 1, furthercomprising: a seal between a forward end of said nozzle link and saidaperture of said second nozzle.
 9. The injection molding apparatus ofclaim 8, wherein the seal is annular and made of a thermally insulativematerial.
 10. The injection molding apparatus of claim 1, wherein underoperating conditions said gate seals are longitudinally fixed inposition and thermal expansion of said second nozzle is accommodated bysaid nozzle link.
 11. The injection molding apparatus of claim 10,wherein said manifold is longitudinally fixed in position such thatunder operating conditions thermal expansion of said first nozzle isaccommodated by said nozzle link.
 12. The injection molding apparatus ofclaim 1, further comprising: a first heater coupled to said firstnozzle; and a second heater coupled to said second nozzle, wherein saidsecond heater is in contact with both a front surface and a back surfaceof said second nozzle body.
 13. The injection molding apparatus of claim1, wherein said second nozzle is axially slidable relative to saidnozzle link under operating conditions.
 14. The injection moldingapparatus of claim 1, wherein said nozzle link melt passage is of asubstantially constant diameter.
 15. An injection molding apparatuscomprising: a manifold having at least one manifold melt channel forreceiving a melt stream of moldable material under pressure; a firstnozzle having a first nozzle melt channel in fluid communication withsaid manifold melt channel; a second nozzle having a nozzle body, asecond nozzle melt channel in fluid communication with said first nozzlemelt channel and a plurality of outwardly extending melt passages influid communication with said second nozzle melt channel; a nozzle linkprovided between the first nozzle and the second nozzle and having anozzle link melt passage of a substantially constant diameter forfluidly coupling the first nozzle melt channel and the second nozzlemelt channel, the nozzle link being threadably attached to the firstnozzle and slidable within an aperture of the second nozzle, whereinsaid second nozzle is axially slidable relative to said nozzle linkunder operating conditions; and a plurality of gate seals coupled tosaid second nozzle, said plurality of gate seals for delivering the meltstream from said plurality of outwardly extending melt passages to aplurality of mold cavities through respective mold gates.
 16. Theinjection molding apparatus of claim 15, wherein said plurality ofoutwardly extending melt passages radially extend from the second nozzlemelt channel and said second nozzle body is substantially puck-shaped.17. The injection molding apparatus of claim 15, wherein a length ofsaid second nozzle body measured along a longitudinal axis of the secondnozzle is less than at least one of a width of said nozzle body and adepth of said nozzle body.
 18. The injection molding apparatus of claim17, wherein said second nozzle body is substantially brick shaped. 19.The injection molding apparatus of claim 15, further comprising: a firstheater coupled to said first nozzle; and a second heater coupled to saidsecond nozzle, wherein said second nozzle heater is in contact with botha front surface and a back surface of said second nozzle body.
 20. Theinjection molding apparatus of claim 15, wherein said plurality of moldcavities are located forward of a front surface of said second nozzle,and said outwardly extending melt passages extend toward the frontsurface of said second nozzle to deliver the melt to the mold cavities.21. The injection molding apparatus of claim 15, wherein said firstnozzle comprises a first material have a first thermal conductivity,said second nozzle comprises a second material have a second thermalconductivity, and said nozzle link comprises a third material have athird thermal conductivity, wherein the third thermal conductivity ishigher than the first thermal conductivity and the second thermalconductivity.
 22. The injection molding apparatus of claim 21, whereinthe first material and the second material are the same.
 23. Theinjection molding apparatus of claim 15, wherein said outwardlyextending melt passages extend toward a front surface of said secondnozzle, and said plurality of gate seals are coupled to said frontsurface of said second nozzle.
 24. The injection molding apparatus ofclaim 1, wherein said first nozzle comprises a first material have afirst thermal conductivity, said second nozzle comprises a secondmaterial have a second thermal conductivity, and said nozzle linkcomprises a third material have a third thermal conductivity, whereinthe third thermal conductivity is higher than the first thermalconductivity and the second thermal conductivity.
 25. The injectionmolding apparatus of claim 24, wherein the first material and the secondmaterial are the same.
 26. The injection molding apparatus of claim 1,wherein said outwardly extending melt passages extend toward a frontsurface of said second nozzle, and said plurality of gate seals arecoupled to said front surface of said second nozzle.